System and method for rapid transitioning of polyolefin processes from one product to another

ABSTRACT

A gas-phase polyolefin reactor system for rapidly transitioning from one polyolefin product to another is disclosed. The reactor system comprises a control valve, a high-flow valve, a polyolefin reactor, a flow meter, a totalizer and an empirical model. During a transition, the empirical model predicts a required amount based upon an initial concentration and a selected ending concentration, the flow meter measures a flow rate, the totalizer determines a totalized amount when the flow rate of the first stream reaches the required amount based upon the measured flow rate and outputs the totalized amount to the empirical model, and the empirical model compares the required amount to the totalized amount and determines a transition endpoint. A method of rapidly transitioning the reactor system from one polyolefin product to another is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.13/930,072, filed on Jun. 28, 2013, now U.S. Pat. No. 8,986,618, for“System and Method for Rapid Transitioning of Polyolefin Processes FromOne Product to Another.”

TECHNICAL FIELD

This invention relates to a system and method for rapidly transitioningfrom one polyolefin product to another within a gas-phase polyolefinreactor to reduce the off-grade material produced during the transition.

BACKGROUND OF THE INVENTION

Control and ability to rapidly transition from one polyolefin product toanother is essential when producing a portfolio of products on agas-phase polyolefin reactor. During the transition, the flow rate ofone or more reactant components (e.g., hydrogen, monomer, co-monomer,co-catalyst and/or catalyst modifier) must be changed. For example, tocontrol and decrease the molecular weight of a polyolefin product, theratio of hydrogen to monomer must be increased. In other words, thehydrogen concentration within the polyolefin reactor determines themolecular weight of the polyolefin product. Molecular weight is a key,measurable property, which determines physical properties in thepolyolefin product. By increasing the hydrogen concentration within thepolyolefin reactor, the molecular weight of the produced polyolefin isdecreased. Hydrogen serves to terminate the polymerization reaction onthe catalyst, and to halt the formation of the polyolefin chain. Anincreased hydrogen concentration (i.e., decreased monomer concentration)results in shorter polyolefin chains, and in a lower molecular weightpolyolefin product.

Conversely, to control and increase the molecular weight of thepolyolefin product, the ratio of hydrogen to monomer must be decreased.By increasing the monomer concentration within the polyolefin reactor,the molecular weight of the produced polyolefin is increased. Anincreased monomer concentration (i.e., decreased hydrogen concentration)results in longer polyolefin chains, and in a higher molecular weightpolyolefin product.

To change other physical properties of the polyolefin product, theco-monomer, co-catalyst and/or catalyst modifier concentration must bechanged. For example, in impact co-polymer (ICP) polypropyleneproduction, the ethylene concentration within the polyolefin reactormust be changed to achieve the specific properties for various ICPgrades. A change in ethylene concentration results in an altered rubbercontent in the produced polyolefin product.

In other words, each polyolefin product has specific physical propertiesthat define that grade. If a produced polyolefin does not have thesephysical properties, it is an off-grade material with an inherently lowvalue. During the transition, the produced polyolefin does not have thephysical properties of either the starting grade or the ending grade.The polyolefin produced during the transition is a low-value, off-gradematerial.

Thus, a system and method is needed to minimize the transition periodand to reduce the production of off-grade material during transitions.

SUMMARY OF THE INVENTION

The present invention takes advantage of the ability to diffuse areactant component in a gas-phase polyolefin reactor to rapidly affectthe physical properties of the polyolefin powder produced by increasingconcentrations of reactant components.

In an embodiment, the present invention can rapidly increase thehydrogen concentration within a gas-phase polyolefin reactor to reducethe molecular weight of the polyolefin. The molecular weight is a key,measurable property which determines physical properties in thepolyolefin product. A rapid change in hydrogen concentration allows fora faster reduction in molecular weight, and, therefore, a much shortertransition period from a higher molecular weight product to a lowermolecular weight product. The accelerated transition decreases theamount of off-grade production and, therefore, reduces operation costs.

Conversely, in an embodiment, the present invention may be applied torapidly increase the monomer concentration within the gas-phasepolyolefin reactor to increase the molecular weight of the polyolefin. Arapid change in monomer concentration allows for a faster increase inmolecular weight, and, therefore, a shorter transition period from alower molecular weight product to a higher molecular weight product.

Further, in an embodiment, the present invention can be applied torapidly increase the co-monomer within the gas-phase polyolefin reactorto change other physical properties in the polyolefin product. Forexample, in ICP polypropylene production, the co-monomer (e.g.,ethylene) could be rapidly changed to alter rubber content in theproduced polyolefin product, and, thereby, achieve the specificproperties for various ICP grades. In polypropylene production, theethylene, 1-butene, 1-hexene and/or 1-octene concentration may bechanged to achieve the specific properties for various grades.

In an embodiment, the present invention could be applied to rapidlyswitch a co-catalyst or catalyst modifier to transition from onepolyolefin product to another. For example, a replacement ofdi-isopropyldimethoxysilane (DIPDMS) with di-isobutyldimethoxysilane(DIBDMS) within the polyolefin reactor would increase the production ofatactic polymer and, thereby, decrease the flexural modulus of theproduced polyolefin product.

These and other objects, features, and advantages will become apparentas reference is made to the following detailed description, preferredembodiments, and examples, given for the purpose of disclosure, andtaken in conjunction with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature and objects of the presentinvention, reference should be made to the following detaileddisclosure, taken in conjunction with the accompanying drawings, inwhich like parts are given like reference numerals, and wherein:

FIG. 1A illustrates a process flow diagram according to an embodiment ofthe invention;

FIG. 1B illustrates a process flow diagram according to a prototype ofthe present invention, which was used to evaluate the invention;

FIG. 2 illustrates a chart of hydrogen amount (lbs) vs. hydrogenconcentration as an exemplary empirical model for a gas-phase polyolefinreactor system according to an embodiment of the present invention,wherein A=14.852*B/(476.544+B), where A=hydrogen concentration, andB=hydrogen amount (lbs);

FIG. 3 illustrates an example of an operator overshoot scenario wherethe operator relies on an online analyzer when adding a high rate ofhydrogen during a transition of molecular weight;

FIG. 4 illustrates an example of a transition scenario where an operatorrelies on melt flow rate (MFR) when adding hydrogen to a recycle gasstream during a transition of molecular weight; and

FIG. 5 illustrates an example of a transition scenario where an operatorrelies on an embodiment of the present invention when adding hydrogen toa recycle gas stream during a transition of molecular weight.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

The following detailed description of various embodiments of the presentinvention references the accompanying drawings, which illustratespecific embodiments in which the invention can be practiced. While theillustrative embodiments of the invention have been described withparticularity, it will be understood that various other modificationswill be apparent to and can be readily made by those skilled in the artwithout departing from the spirit and scope of the invention.Accordingly, it is not intended that the scope of the claims appendedhereto be limited to the examples and descriptions set forth herein butrather that the claims be construed as encompassing all the features ofpatentable novelty which reside in the present invention, including allfeatures which would be treated as equivalents thereof by those skilledin the art to which the invention pertains. Therefore, the scope of thepresent invention is defined only by the appended claims, along with thefull scope of equivalents to which such claims are entitled.

Gas-Phase Polyolefin Reactor System

A process flow diagram according to an embodiment of the presentinvention is illustrated in FIG. 1A. In particular, FIG. 1A shows aprocess flow diagram for a gas-phase polyolefin process 100. Examples ofsuitable polyolefin processes include, but are not limited to,polyethylene, polypropylene and polybutene. Suitable polyethyleneprocesses are available from Ineos Technologies (e.g., INNOVENE™ GProcess) or Univation Technologies (e.g., UNIPOL™ PE Process); andsuitable polypropylene processes are available from Dow Chemical (e.g.,UNIPOL™ PP Process) or Ineos Technologies (e.g., INNOVENE™ PP Process).

An input stream 105 comprises a reactant component (e.g., hydrogen)coming from a header (not shown). A header is a pipe which contains themain supply of a reactant component or a mixture of reactant components.In an embodiment, the reactant component (e.g., hydrogen) may besupplied from the header to a gas-phase polyolefin reactor 160 through acontrol valve 110 or through a high-flow valve 130.

The input stream 105 comprising the reactant component (e.g., hydrogen)is directed through a steady-state control valve 110 or through ahigh-flow valve 130. The steady-state valve 110 supplies a continuousstream (i.e., constant flow) of reactant component to the gas-phasepolyolefin reactor 160 during normal operations to maintain specificproduct properties. Suitable examples of steady-state, bypass valves andhigh-flow valves include, but are not limited to, sliding stem valvesand other types of valves. A flow range of the valve relative to normaloperating conditions is more important than any specific type of valve.A suitable valve is available from Emerson Process Management (e.g.,FISHER™ Sliding Stem Control Valve). The high-flow valve 130 has a flowmeter 180, which outputs a measured flow rate to a totalizer 185. In anembodiment, the flow meter 180 is an orifice plate which provides theflow rate through an upstream high-flow valve 130 via calculations.Examples of suitable flow meters include, but are not limited to,orifice plates and other types of flow measurement devices. A suitableflow meter is available from Emerson Process Management (e.g.,ROSEMOUNT™ Conditioning Orifice Flowmeter). The totalizer is analgorithm to calculate the amount of reaction component added to thepolyolefin reactor 160 based on the input measured flow rate from theflow meter 180. Examples of suitable totalizers include, but are notlimited to, Distributed Control System (DCS) algorithms and other typesof totalizing algorithms. A suitable totalizer is available fromHoneywell (e.g., DCS algorithm).

During normal operation, the input stream 105 is directed through asteady-state control valve 110. When the steady-state control valve 110is used, the input stream 105 comprising the reactant component (e.g.,hydrogen) enters via stream 140 into stream 145.

During a transition, a limiting factor is the flow rate of the reactantcomponent within a gas-phase polyolefin reactor 160. Examples ofsuitable gas-phase polyolefin reactors include, but are not limited to,gas-phase horizontal polyolefin reactors and any other type of gas-phasepolyolefin reactor. A suitable gas-phase polyolefin reactor is availablefrom Nooter Corporation (e.g., 8-foot 0-inch I.D. Homopolymer Reactor).

Generally, a flow rate of at least 200% over a maximum steady-stateoperation is desired to transition from one polyolefin product toanother within the polyolefin reactor 160. Alternatively, the desiredtransition flow rate may be about 100 lbs/hour over the maximumsteady-state operation (e.g., 30 lbs/hour). At lower flow rates, thetransition may occur too slowly and result in prolonged off-gradeproduction. In an embodiment, the transition flow rate may be from about200% to about 5000% over the maximum steady-state operation.Alternatively, the transition flow rate may be about 100 lbs/hour toabout 2500 lbs/hour.

At some point with higher flow rates, the header pressure of inputstream 105 supplying the reactant component will drop, and the stream140 will no longer have sufficient pressure to enter the recycle gassystem (i.e., stream 145). Further, the reactant component can be addedso rapidly that accuracy of a totalizer 185 is diminished. It is alsopossible that the addition of a very large amount of any given reactantcomponent could cause a reactor 160 upset.

During a transition, input stream 105 comprising the reactant component(i.e., hydrogen) is directed through the high-flow valve 130 to stream140, which enters stream 145. Stream 145 carries the reactant component(e.g., hydrogen) into the gas-phase polyolefin reactor 160.

The empirical model 190 receives input from an online analyzer 195(e.g., off-gas analyzer), which measures the concentration of thereactant component (e.g., hydrogen). Examples of suitable onlineanalyzers include, but are not limited to, gas chromatographs and massspectrometers. A suitable online analyzer is available from Yokogawa(e.g., GC1000 MARK II™).

At the beginning of any transition, the empirical model 190 receivesinput from the online analyzer 195, which measures a startingconcentration of the reactant component (e.g., hydrogen). The empiricalmodel 190 predicts a required amount (lbs) of reactant component (e.g.,hydrogen) necessary to complete the transition based upon the measuredstarting concentration of the reactant component (e.g., hydrogen) and adesired ending concentration of the reactant component (e.g., hydrogen).

The totalizer 185 receives input from the flow meter 180, which measuresa flow rate of the reactant component (e.g., hydrogen). Based upon themeasured flow rate of the reactant component (i.e., input stream 105),the totalizer 185 determines when the reactant component (e.g.,hydrogen) flow rate into the polyolefin reactor 160 reaches the requiredamount (lbs) of reactant component. The empirical model 190 compares therequired amount (lbs) of reactant component (e.g., hydrogen) tototalized amount (lbs) of reactant component to determine a transitionendpoint, and outputs the transition endpoint to the totalizer 185. Bypredicting the endpoint of the transition, the totalizer 185 is able tosimultaneously shut-off the flow of reactant component (e.g., hydrogen)at the transition endpoint via the high-flow valve 130. Once thehigh-flow valve 130 adds the required amount (lbs) of reactant component(e.g., hydrogen), the high-flow valve 130 is closed and the transitionis complete.

Prototype Gas-Phase Reactor System for Testing Present Invention

A process flow diagram according to a prototype of the present inventionis illustrated in FIG. 1B. In particular, FIG. 1B shows a process flowdiagram for a gas-phase polyolefin process 100. In this example, anIneos Technologies polypropylene process (i.e., INNOVENE™ PP Process)was used to evaluate the present invention.

An input stream 105 comprises a reactant component (e.g., hydrogen)coming from a header (not shown). The reactant component (e.g.,hydrogen) was supplied from the header to a gas-phase polyolefin reactor160 through a control valve 110 or through a bypass valve 115 and ahigh-flow valve 130.

The input stream 105 comprising the reactant component (e.g., hydrogen)was directed through a steady-state control valve 110 or through abypass valve 115 and a high-flow valve 130. The steady-state valve 110supplied a continuous stream (i.e., constant flow) of reactant componentto the gas-phase polyolefin reactor 160 during normal operations tomaintain specific product properties. In this example, an EmersonProcess Management valve (e.g., FISHER™ Sliding Stem Control Valve) wasused for the evaluation. The high-flow valve 130 has a flow meter 180,which outputs a measured flow rate to a totalizer 185. In this example,an Emerson Process Management flow meter (e.g., ROSEMOUNT™ ConditioningOrifice Flowmeter) and a Honeywell totalizer (e.g., DCS algorithm) wereused for the evaluation.

During normal operation, the input stream 105 was directed through asteady-state control valve 110. When the steady-state control valve 110is used, the input stream 105 comprising the reactant component (e.g.,hydrogen) entered via stream 140 into stream 145 on a low-pressure side(i.e., suction side) of a compressor 150.

During transitions, the limiting factor was the flow rate of thereactant component within a gas-phase polyolefin reactor 160. Generally,a flow rate of at least 200% over a maximum steady-state operation wasdesired to transition from one polyolefin product to another within thepolyolefin reactor 160. Alternatively, the desired transition flow ratewas at least 100 lbs/hour over the maximum steady-state operation (i.e.,30 lbs/hour). At lower flow rates, the transition occurred too slowlyand resulted in prolonged off-grade production.

During the evaluation, inventors discovered that an achievable upperlimit on the flow rate of the reactant component was about 2000% toabout 5000% over the maximum steady-state operation. Alternatively, thetransition flow rate was about 1,000 lbs/hour to about 2500 lbs/hour.Generally, this value depends on the maximum steady-state flow rateduring operation, and, therefore, a lower maximum steady-state operationmay result in a transition flow rate up to about 5000% over the maximumsteady-state operation.

The inventors also discovered during the evaluation that adding thereactant component (e.g., hydrogen) through the high-flow valve 130 tostream 145 on the low pressure side (i.e., suction side) of thecompressor 150 caused surging in the compressor 150. To minimizepotential damage to the compressor 150, stream 125 comprising thereactant component (e.g., hydrogen) entered via stream 135 into stream155 on the high pressure side (i.e., discharge side) of the compressor150.

During a transition, the input stream 105 comprising the reactantcomponent (i.e., hydrogen) was redirected around the steady-statecontrol valve 110 via a bypass valve 115 and streams 120, 125. Thebypass valve 115 achieved a much higher flow rate than the control valve110. When the bypass valve 115 was used, stream 105 comprising thereactant component (i.e., hydrogen) entered via stream 140 into stream145 on a low-pressure side (i.e., suction side) of a compressor 150. Thecompressor 150 compresses the reactant component (e.g., hydrogen) to apressure required for the polyolefin reactor 160.

Stream 155 carried the reactant component (e.g., hydrogen) into thegas-phase polyolefin reactor 160. Stream 165 comprised a reactor recyclegas coming from the polyolefin reactor 160. Stream 165 comprising thereactor recycle gas was directed through a heat exchanger 170. The heatexchanger 170 cooled stream 165 comprising the reactor recycle gas intogas- and liquid-phase components. Cooled stream 165 carried the gas- andliquid-phase components to a separator tank 175. The separator tank 175held the gas- and liquid-phase components from the heat exchanger 170.The liquid-phase components were pumped to the polyolefin reactor 160,and the gas-phase components were compressed by the compressor 150 andrecycled to the polyolefin reactor 160. Stream 145 comprising thegas-phase components (and the reactant component (e.g., hydrogen) fromstream 140) coming from the separator tank 175 entered on a low-pressureside (i.e., suction side) of a compressor 150.

The empirical model 190 received input from an online analyzer 195(e.g., off-gas analyzer), which measured the concentration of thereactant component (e.g., hydrogen). In this example, a Yokogawa onlineanalyzer (i.e., GC1000 MARK II™) was used for the evaluation.

At the beginning of any transition, the empirical model 190 receivedinput from the online analyzer 195, which measured a startingconcentration of the reactant component (e.g., hydrogen). The empiricalmodel 190 predicted a required amount (lbs) of reactant component (e.g.,hydrogen) necessary to complete the transition based upon the measuredstarting concentration of the reactant component (e.g., hydrogen) and adesired ending concentration of the reactant component (e.g., hydrogen).

The totalizer 185 received input from the flow meter 180, which measuresa flow rate of the reactant component (e.g., hydrogen). Based upon themeasured flow rate of the reactant component (i.e., input stream 125),the totalizer 185 determined a totalized amount when the flow rate ofthe input stream 125 reached the required amount (lbs) of reactantcomponent, and output the totalized amount (lbs) to the empirical model190. The empirical model 190 compared the required amount of reactantcomponent to the totalized amount and determined a transition endpoint,and output the transition endpoint to the totalizer 185. By predictingthe transition endpoint, the totalizer 185 was able to simultaneouslyshut-off the flow of reactant component (e.g., hydrogen) at theappropriate time via the high-flow valve 130 rather than requiring anoperator to oversee the addition of hydrogen, which introducesassociated risks of human error and inexperience.

Example of Empirical Model for a Gas-Phase Polyolefin Reactor System

An exemplary empirical model for a gas-phase polyolefin reactor systemaccording to an embodiment of the present invention is illustrated inFIG. 2. In particular, FIG. 2 shows a chart of hydrogen amount (lbs) vs.hydrogen concentration as an empirical model to rapidly increase thehydrogen concentration within the gas-phase polyolefin reactor todecrease the molecular weight of the polyolefin (e.g. polypropylene).

Data for this empirical model 190 was collected from observedtransitions between different molecular weight products in the gas-phasepolyolefin reactor 160. The model utilized data measured by an onlineanalyzer 195 of the hydrogen concentration within the reactor recyclegas system (i.e., stream 145). Also, data on the hydrogen amount (lbs)added to the polyolefin reactor 160 during these transitions wasmeasured by the flow meter 180 and incorporated into the model.

The empirical model 190 correlates these two sets of data using aMichaelis-Menten fit and predicts the hydrogen amount (lbs) necessary tocomplete a transition between two different hydrogen concentrations. Thefitted line plot isA=14.852*B/(476.544+B)where

A=hydrogen concentration, and

B=hydrogen amount (lbs).

The empirical model 190 can be used to determine the hydrogen amount(lbs) required for a transition of molecular weight of polypropylenepowder produced within the polyolefin reactor 160 because a change inhydrogen concentration in the recycle gas system (i.e., stream 145)affects the molecular weight of the powder produced within thepolyolefin reactor 160. For example, a transition from a polypropylenepowder requiring a hydrogen concentration of 1 to a polypropylene powderrequiring a hydrogen concentration of 3 would require a hydrogen amountof about 86 lbs to complete the transition. (See FIG. 2). The amount ofhydrogen required is the difference between the starting point and theending point.

At the beginning of any transition, the empirical model 190 receivesinput from the online analyzer 195, which measures a startingconcentration of the reactant component (e.g., hydrogen). The empiricalmodel 190 predicts a required amount (lbs) of reactant component (e.g.,hydrogen) necessary to complete the transition based upon the measuredstarting concentration of the reactant component (e.g., hydrogen) and adesired ending concentration of the reactant component (e.g., hydrogen).

The totalizer 185 determines a totalized amount when the flow rate ofthe input stream 105 reaches the required amount of reaction componentbased upon the measured flow rate, and outputs the totalized amount tothe empirical model 190. The empirical model 190 compares the requiredamount of reactant component to the totalized amount to determine atransition endpoint, and outputs the transition endpoint to thetotalizer 185. By predicting the transition endpoint, the totalizer 185is able to simultaneously shut-off the flow of reaction component (e.g.,hydrogen) at the transition endpoint via the high-flow valve 130 ratherthan requiring an operator to oversee the addition of hydrogen, whichintroduces associated risks of human error and inexperience.

Although this exemplary empirical model relates to the rapid increase ofhydrogen concentration within the polyolefin reactor to decrease themolecular weight of the polyolefin (e.g., polypropylene), a person ofordinary skill in the art (POSITA) could easily apply this teaching torapidly increase the monomer (e.g., propylene) concentration (i.e.,effectively decrease the hydrogen concentration) within the polyolefinreactor to increase the molecular weight of the polyolefin (e.g.,polypropylene), as discussed above.

Further, the POSITA could easily extend this teaching to other gas-phasepolyolefin processes and/or reactant components. For example, theempirical model could be fine-tuned to rapidly transition the co-monomer(e.g., ethylene, 1-butene, 1-hexene, 1-octene), co-catalyst (e.g.,tetraethylammonium iodide (TEAI)) or catalyst modifier (e.g.,di-isopropyldimethoxysilane (DIPDMS), di-isobutyldimethoxysilane(DIBDMS)) to change the physical properties of the polyolefin (e.g.,polypropylene) in polyolefin production. In an embodiment, theco-monomer (e.g., ethylene, 1-butene, 1-hexene and/or 1-octene) could berapidly increased within the polyolefin reactor to change the physicalproperties of the polyolefin (e.g., polypropylene) in polyolefinproduction. In ICP polyolefin production, the co-monomer (e.g.,ethylene) could be rapidly changed to alter rubber content in theproduced polyolefin product, and, thereby, achieve the specificproperties for various ICP grades. In an embodiment, the catalystmodifier could be rapidly switched from DIPDMS to DIBDMS to increase theproduction of atactic polymer and, thereby, decrease the flexuralmodulus of the produced polyolefin product.

Method for Rapid Transitioning

In an embodiment, the method for rapid transitioning a gas-phasepolyolefin reactor system from one polyolefin product to anothercomprises the steps of selecting an ending reactant componentconcentration; measuring a starting reactant component concentrationwith an online analyzer 195 to obtain a measured starting reactantcomponent concentration; predicting a required amount of reactantcomponent with an empirical model 190 based upon the measured startingreactant component concentration and the selected ending reactantcomponent concentration; measuring a flow rate of an input stream 105near an input end of a high-flow valve 130 with a flow meter 180;estimating a required time to inject the required amount of reactioncomponent with a totalizer 185 based upon the measured flow rate of theinput stream 105.

In an embodiment, the reactant component may be selected from the groupconsisting of hydrogen, monomers, co-monomers, co-catalysts and catalystmodifiers. In an embodiment, the reactant component may be selected fromthe group consisting of hydrogen, ethylene, propylene, 1-butene,1-hexene and 1-octene. In an embodiment, the co-catalyst may be TEAI. Inan embodiment, the catalyst modifier may be selected from the groupconsisting of DIPDMS and DIBDMS.

In an embodiment, the method further comprises the step of closing thehigh-flow valve simultaneously with the addition of the required amountof reactant component. In an embodiment, the high-flow valve may beautomatically closed.

Example of an Operator Overshoot During a Transition of Molecular Weight

An example of an overshoot scenario where an operator relies on anonline analyzer when adding a high rate of reactant component (i.e.,hydrogen) during a transition of molecular weight is illustrated in FIG.3. As discussed above, examples of on-line analyzers include, but arenot limited to, gas chromatographs and mass spectrometers.

In particular, FIG. 3 shows an operator overshoot scenario where theoperator relies on the online analyzer when adding the reactantcomponent (i.e., hydrogen) at an increased rate during a transition ofthe molecular weight. In FIG. 3, the predicted instantaneous melt flowrate (MFR) and the lab-tested MFR of the polypropylene powder are shownfor the transition. MFR is a measurement of the polypropylene powderviscosity and is inversely related to the molecular weight of theproduct (i.e., a decrease in the molecular weight is an increase in theMFR). In this example, a polypropylene powder with a target MFR of about9 g poly/10 min. is transitioned to a polypropylene powder with a targetMFR of about 25 g polymer/10 min±2.5 g polymer/10 min.

Since the operator did not have an empirical model to predict therequired amount of reactant component (i.e., hydrogen) for thetransition or a totalizer to determine a required time to inject therequired amount of reactant component, the operator misjudged the endpoint (i.e., added too much hydrogen), resulting in an overshoot of thespecified range of acceptable MFR for the product. The data measured bythe on-line analyzer (e.g., gas chromatograph) has an inherent timedelay due to the time required for the analyzer to complete theanalysis. Accordingly, the operator was required to stay off-grade bythe high MFR lab result (i.e., produced off-grade material) for anadditional hour until the MFR was within the specified MFR range.

In this example, the operator also overcompensated (i.e., added toolittle hydrogen) in reducing the MFR, which resulted in an undershot ofthe MFR. Again, the operator was required to stay off-grade by the lowMFR lab result (i.e., produced off-grade material) until the MFR waswithin the specified range. As can be seen by FIG. 3, operators havedifficulty predicting the required key reactant gas (i.e., hydrogen)amount due to the time delay in the data, which results in theproduction of off-grade material.

Although this example is fairly extreme, the risk of overshoot at highrates of reactant component (e.g., hydrogen) addition without using apredictive empirical model or a totalizer is genuine. Accordingly,unlike this example, the present invention requires the use of apredictive empirical model 190 and a totalizer 185 to control theaddition of reactant component (e.g., hydrogen) at a high rate and tominimize a risk of overshooting a required amount.

Example of Traditional Molecular Weight Transition

A transition of molecular weight in a gas-phase polyolefin reactor 160requires a change in hydrogen concentration in a recycle gas stream 145.An example of a transition scenario where an operator relies on anonline analyzer when adding hydrogen to the recycle gas stream 145during a transition of molecular weight is illustrated in FIG. 4. Inthis example, the operator was limited by the low flow rate of thesteady-state control valve 110 (i.e., about 30 lbs/hour) to transitionfrom one polyolefin product to another.

In FIG. 4, the predicted instantaneous MFR of the polypropylene powderis shown for the transition. MFR is a measurement of the polypropylenepowder viscosity and is inversely related to the molecular weight of theproduct (i.e., a decrease in the molecular weight is an increase in theMFR), as discussed above. In this example, a polypropylene powder with atarget MFR of about 10 g polymer/10 min. is transitioned to apolypropylene powder with a target MFR of about 25 g polymer/10 min±5 gpolymer/10 min.

In the traditional transition technique, an input stream 105 comprises areactant component (i.e., hydrogen) coming from a header (not shown).(See e.g., FIG. 1B: 105). The input stream 105 comprising the reactantcomponent (i.e., hydrogen) is directed through a steady-state controlvalve 110. (See e.g., FIG. 1B: 105, 110). During transition, thereactant component (i.e., hydrogen) is regulated by a control valve 110normally used for steady-state operation. (Id.). The input stream 105comprising the reactant component (i.e., hydrogen) enters via stream 140into stream 145 on a low-pressure side (i.e., suction side) of acompressor 150. (See e.g., FIG. 1B: 105, 140, 145 & 150). Duringtransition, the hydrogen control valve 110 is opened to a maximum. Atthe valve's maximum, the hydrogen flow rate is about 30 lbs/hour.

At a maximum flow rate of about 30 lbs/hour, the transition from thepolypropylene powder with a MFR of about 10 g polymer/10 min. to thepolypropylene powder with a low range MFR of about 20 g polymer/10 min.is estimated by the instantaneous MFR model to be achieved in about 4hours, which results in the production of about 184,100 lbs of off-gradematerial.

This example is representative of traditional transitions from onepolyolefin product to another, and the risk of overshoot at high ratesof reactant component (e.g., hydrogen) addition without using apredictive empirical model or a totalizer is genuine.

Accordingly, unlike this example, the present invention requires ahigh-flow valve 130 to permit the addition of reactant component (e.g.,hydrogen) at a high rate and to minimize production of off-gradematerial.

Example of Rapid Hydrogen Addition for Molecular Weight Transition

An example of a transition scenario where an operator relies on anembodiment of the present invention when adding hydrogen to a recyclegas stream during a transition of molecular weight is illustrated inFIG. 5. In this example, the operator was not limited by the low-flowrate of the steady-state control valve 110 (e.g., about 30 lbs/hour) totransition from one polyolefin product to another. Instead, the operatorwas able to bypass the steady-state control valve 110 through a bypassvalve 115 and a high-flow valve 130.

In FIG. 5, the predicted instantaneous MFR of the polypropylene powderis shown for the transition. In this example, a polypropylene powderwith a target MFR of about 7.5 g polymer/10 min. was transitioned to apolypropylene powder with a target MFR of about 25 g polymer/10 min.±5 gpolymer/10 min. This molecular weight transition was conducted on thesame equipment as the previous example—a gas-phase polyolefin reactor160, and required the addition of hydrogen to the recycle gas stream155.

In the experimental technique according to a prototype of the presentinvention, an input stream 105 comprises a reactant component (i.e.,hydrogen) coming from a header (not shown). (See FIG. 1B). Duringtransition, the input stream 105 comprising the reactant component(i.e., hydrogen) was redirected around the steady-state control valve110 via a manual bypass valve 115. (Id.). The bypass valve 115 achieveda much higher flow rate than the control valve 110. (Id.).

The input stream 105 comprising the reactant component (i.e., hydrogen)entered via stream 140 into stream 145 on a low-pressure side (i.e.,suction side) of a compressor 150. (See FIG. 1).

During this transition experiment, the hydrogen flow rate was notmetered or measured; however, the hydrogen flow rate was calculated atabout 500 lbs/hour. At a flow rate of about 500 lbs/hour, the transitionfrom the polypropylene powder with a MFR of about 10 g polymer/10 min.to the polypropylene powder with a low range MFR of about 20 gpolymer/10 min. is estimated by the instantaneous MFR model to beachieved in about 1.3 hours, which results in the production of about47,500 lbs of off-grade material.

Comparison of this and the previous example shows that the rapidaddition of hydrogen completes the molecular weight transitionsignificantly faster than the traditional technique (i.e., about 1.3hours compared to about 4 hours). Further, the faster transitionsignificantly reduced the production of off-grade material as a resultof the transition (i.e., about 47,500 lbs compared to about 184,100lbs). As demonstrated by these examples, the present invention minimizesthe transition period and significantly reduces the production ofoff-grade material during transitions.

Further, the present invention expands on these experimental results andapplies process controls with the empirical model 190, totalizer 185,and online analyzer 195. This system and method provides a low-risktechnique of achieving a quick, cost-effective transition.

The embodiments and examples set forth herein are presented to bestexplain the present invention and its practical application and tothereby enable those skilled in the art to make and utilize theinvention. However, those skilled in the art will recognize that theforegoing description and examples have been presented for the purposeof illustration and example only. The description as set forth is notintended to be exhaustive or to limit the invention to the precise formdisclosed. Many modifications and variations are possible in light ofthe above teaching without departing from the spirit and scope of thefollowing claims.

DEFINITIONS

As used herein, the terms “a,” “an,” “the,” and “said” when used inconjunction with the term “comprising” means one or more, unless thecontext dictates otherwise.

As used herein, the term “about” means the stated value plus or minus amargin of error or plus or minus 10% if no method of measurement isindicated.

As used herein, the term “or” means “and/or” unless explicitly indicatedto refer to alternatives only or if the alternatives are mutuallyexclusive.

As used herein, the terms “comprising,” “comprises,” and “comprise” areopen-ended transition terms used to transition from a subject recitedbefore the term to one or more elements recited after the term, wherethe element or elements listed after the transition term are notnecessarily the only elements that make up the subject.

As used herein, the terms “containing,” “contains,” and “contain” havethe same open-ended meaning as “comprising,” “comprises,” and“comprise,” provided above.

As used herein, the terms “having,” “has,” and “have” have the sameopen-ended meaning as “comprising,” “comprises,” and “comprise,”provided above.

As used herein, the terms “including,” “includes,” and “include” havethe same open-ended meaning as “comprising,” “comprises,” and“comprise,” provided above.

As used herein, the phrase “consisting of” is a closed transition termused to transition from a subject recited before the term to one or morematerial elements recited after the term, where the material element orelements listed after the transition term are the only material elementsthat make up the subject.

As used herein, the phrase “consisting essentially of” occupies a middleground, allowing the addition of non-material elements that do notsubstantially change the nature of the invention, such as variousbuffers, differing salts, extra wash or precipitation steps, pHmodifiers, and the like.

As used herein, the term “simultaneously” means occurring at the sametime or about the same time, including concurrently.

INCORPORATION BY REFERENCE

All patents and patent applications, articles, reports, and otherdocuments cited herein are fully incorporated by reference to the extentthey are not inconsistent with this invention.

What is claimed is:
 1. A gas-phase polyolefin reactor system,comprising: a) a control valve, wherein a first stream is connected toan input end of the control valve and to an input end of a high-flowvalve and a second stream is connected to an output end of the controlvalve and the high-flow valve, wherein the second stream is connected toa third stream, wherein the third stream is connected to an input of agas-phase polyolefin reactor; b) wherein the first, second and thirdstreams comprise a reaction component, wherein an empirical modelpredicts a required amount of a reaction component based upon an initialconcentration and a selected ending concentration, and wherein a flowmeter measures a flow rate of the first stream near the input end of thehigh-flow valve and outputs the measured flow rate to a totalizer. 2.The system of claim 1, wherein an on-line analyzer measures the initialconcentration of the reaction component in the third stream upstreamfrom the gas-phase polyolefin reactor.
 3. The system of claim 1, whereinthe totalizer determines a totalized amount when the flow rate of thefirst stream reaches the required amount of reaction component basedupon the measured flow rate and outputs the totalized amount to theempirical model.
 4. The system of claim 3, wherein the empirical modelcompares the required amount of reactant component to the totalizedamount to determine a transition endpoint.
 5. The system of claim 1,wherein the reactant component is selected from the group consisting ofhydrogen, monomers, co-monomers, co-catalysts and catalyst modifiers. 6.The system of claim 5, wherein the reactant component is selected fromthe group consisting of hydrogen, ethylene, propylene, 1-butene,1-hexene and 1-octene.
 7. The system of claim 6, wherein the reactantcomponent is hydrogen.
 8. The system of claim 6, wherein the reactantcomponent is ethylene.
 9. The system of claim 6, wherein the reactantcomponent is propylene.
 10. The system of claim 6, wherein the reactantcomponent is 1-butene, 1-hexene or 1-octane.
 11. The system of claim 5,wherein the reactant component is selected from the group consisting ofco-catalysts and catalyst modifiers.
 12. The system of claim 9, whereinthe co-catalyst is TEAI.
 13. The system of claim 9, wherein the catalystmodifier is selected from the group consisting of DIPDMS, DIBDMS andother organosilanes.
 14. The system of claim 9, wherein the catalystmodifier is selected from the group consisting of DIPDMS, DIBDMS andother dimethoxysilanes.
 15. The system of claim 9, wherein the catalystmodifier is selected from the group consisting of DIPDMS and DIBDMS. 16.The system of claim 1, wherein the flow rate through the high-flow valveis from about 100 lbs/hour to about 2,500 lbs/hour.
 17. The system ofclaim 1, wherein the flow rate through the high-flow valve is from about100 lbs/hour to about 1,000 lbs/hour.